Clutch System
GENERAL
(GENERAL won
LUBRICANTS...
SPECIALTOOLS oe
TROUBLESHOOTING Cea
CLUTCH SYSTEM
‘COMPONENTS:
BLEEDING
CLUTCH MASTE!
COMPONENTS sn =CH-7
REMOVAL. "CH-7
INSPECTION = CH-8
INSTALLATION. eH-9
DISASSEMBLY “OH-9
INSPECTION... “CH-9
REASSEMBLY
CLUTCH PEDAL
‘COMPONENTS ..
REMOVAL.
INSPECTION.
INSTALLATION re
CLUTCH COVER AND DISC
‘COMPONENTS.
REMOVAL ..
INSPECTION
INSTALLATION
CLUTCH RELEASE CYLINDER
‘COMPONENTS.
REMOVAL. cH-17
INSPECTION cH-18
DISASSEMBLY . cH-B
INSPECTION... cH-18
REASSEMBLY cH-18
INSTALLATION CH-19c
GENERAL
GENERAL sercrom
‘SPECIFICATIONS
tem
Clutch operating method
Clutch dise
‘We
Facing diameter (Outside x Inside) mm
Clutch cover assembly
CLUTCH SYSTEM
Specifications
Hydraulic type
Single dry with diaphragm.
1.3SOHC, 1.5Diesol : 184 x 127.5
1.SSOHC, 1.5DOHC : 200 x 130
A.6DOHC : 215 x 145
‘Type Diaphragm spring strap
‘Clutch release cylinder
= LD. mm (in) 20.64 (081)
Clutch master cylinder
LD. mm (in.) 15.57 (0.62)
* LD. : Inside Diameter
‘SERVICE STANDARD
Hem
(Clutch disc thickness [When free}
Clutch pedal free play
‘Standard value
1.3SOHC, 1.5Diesel ; 8.4 + 0.3 mm
1.5SOHC, 1.5 DOHC, 1.6D0HC ; 8.5 + 0.3 mm
6 ~ 13 (0.24 ~ 0.52)
Clutch pedal height 1687 (6.8)
Clutch pedal stroke 145 (5.6)
Unit = mm (inch)
TIGHTENING TORQUE
tem Nm kgm Io
‘Clutch fpedal to pedal support member 19-28 180 ~ 280 13 ~ 20
CCiutch pedal support member to master cylinder 8-10 80 ~ 100 6-7
Clutch tube flare nut 13-17 190 ~ 170 9-13
Clutch tube bracket 4-6 40 ~ 60 3-4
Clutch release cylinder mounting bolt 15 ~ 22 150 ~ 220 11-16
Clutch release cylinder union bolt 25 250 18
Clutch cover assembly 18~ 22 150 ~ 220 1-16
Clutch master cylinder push rod nut 9-14 90 ~ 140, 6-10
Ignition lock nut 8-10 80 ~ 100, 6-7
Master cylinder reservior band 8-7 50 ~ 70 3-5GENERAL
GENERAL eee
LUBRICANTS arnce
cl
ems ‘Specified lubricants ‘Quantity
‘Contact surface of release bearing and ‘CASMOLY L9508 ‘As required
fulcrum of clutch release fork
Inner surface of clutch release bearing CASMOLY L9508 [As required
Inner surface of clutch release cylinder and outer | Brake fluid DOTS or DOT4 ‘As required
‘circumference of piston and cup
Inner surface of clutch disc spline ‘CASMOLY L9508 ‘As required
Inner surface of clutch master cylinder and outer | Brake fluid DOTS or DOTS ‘As required
circumference of piston assembly
‘Clutch master cylinder push rod, clevis ‘Wheel bearing grease SAE J310a, NLGI No.2 | As required
pin and washer
‘Clutch pedal shaft and bushings ‘SAE J310a, Chassis grease, NLGI-No.1__| As required
Contact portion of release fork to release ‘CASMOLY 19508 ‘As required
cylinder push rod
SPECIAL TOOLS serous
‘Tool (Number and name) Mustration Use
‘09411-25000 Installation of the clutch disc
Clutch dise guidecH CLUTCH SYSTEM
TROUBLESHOOTING | rz28e
Symptom Probable cause Remedy
Clutch sipping insufficient clutch pedal free play “adjust
+ Garwilnot respond to engine | Clogged hydraulic system Correct or replace
speed during acceleration pans
+ Insufcient vehicle speed | Excossive wear of clutch disc facing Replace
+ Lack of power during Hardaned clutch dsc facing, or oll on surface oplace
uphill ving Damaged pressure plata or fiywheo! place
Weak or broken pressure spring Roplace
Difficut gear shiting (gear | Excessive pedal treo play ‘Adjust
noise during shiting) Hydraulic system tid eaks, air tapping or clogging | Repair or replace
parts
Unusual wear or corosion of clutch ese spine Replace
Excessive vibration (distortion) of clutch disc Replace
Giutch | when etuteh fe not | Insufficient play of eutch pedal Adust
noisy | used Excessive wear of cich dso facing Replace
‘Rnoise is heard ater | Unusual wear andlor damage of release bearing Replace
clutch is disengaged
‘Anoise is heard when | ineuffcient grease onthe siding surface of bearing sleeve | Repair
clutch is aisengaged | improperly installed clutch assembly or bearing Repair
noise is heard | Damaged pilot bushing Replace
when car is suddenly
rolled with clutch
parlaly engaged
Difficult to depress clutch pedal _| Insufficient lubrication of clutch pedal Repair
Insufficient lubrication of the lutch dis spine Repair
insufiiont lubrication ofthe clutch relaase lever shaft | Ropair
Insuticient lubrication of font bearing retainer Repair
Difficult to shi gear or cannot | Excessive clutch pedal foo play excessive ‘Adjust pedal roe play
shift at al Clutch release cylinder fauty Repair release
ylindor
Clutch cise out of rus, runoutis excsssive or tning broken | Inspect clutch disc
Spline on input shaft or clutch cee dirty or bured Repair as necessary
‘ Clutch pressure plate fully Replace clutch cover
‘Clutch slips Clutch pedal free play insufficient Adjust pedal free play
Clutch grabs/chatters
(Clutch noisy
Clogged hydraulic system
Clutch lise lining oily oF worn out
Pressure plato faulty
Release fork binding
Clutch disc lining oily oF worn out
Pressure plate faulty
Clutch diaphragm spring bent
‘Worn or broken torsion spring
Engine mounts loose
Damaged clutch pedal bushing
Loose prt inside housing
Release bearing worn or dirty
Release fork or linkage sticks
Repair or replace
parts
Inspect clutch disc
Roplace clutch cover
Inspect release fork
Inspect clutch disc
Replace clutch cover
Replace clutch cover
Replace clutch dise
Repair as necessary
Replace clutch pedal
bushing
Repair as necessary
Replace release
bearing
Repair as necessaryCLUTCH SYSTEM
CLUTCH SYSTEM
CLUTCH CONTROL eo:
COMPONENTS
CH-5
ae \,
1
‘Clutch master cylinder ®D
TORQUE : N-m (kg-cm, Ib-ft)cH6 CLUTCH SYSTEM
SS _LCH SYSTEM
INSPECTION | conuce
BLEEDING
‘Whenever the clutch tube, the clutch hose, andior the
‘clutch master cylinder have been removed, orf the clutch
‘pedal is spongy, bleed the system.
Q) caution
Use the specified fluid. Avoid mixing ditterent
brands of fluid. Specified fluid : SAE J1703 (DOT
3 or DOT 4).
1. Loosen the blesder screw at the clutch release cyl
der.
2. Push the clutch pedal down slowly until allis expelled.
‘3. Hold the clutch pedal down unti the bleeder is retight-
ened,
4. Refill the clutch master cylinder with the specitied
fluid,
As qaumion
‘The rapidly-repeated operation of the clutch pedal
in'@€ range’ may cause the relees oyders
Boston tobe fred out rom ie flees oe
Ger body during a eedng” Reprose te etch
pedal afer rtens tine *4"poin sonpicelCLUTCH SYSTEM CH-7
CLUTCH MASTER CYLINDER
COMPONENTS tomso
9~ 14 (90 ~ 140, 6~ 10)
Master cylinder body
TORQUE : N-m(kg-cm, Ib-ft)
t
REMOVAL «sores
1. Drain the clutch fluid through the bleeder screw.CLUTCH SYSTEM CH-9
INSPECTION sass: ‘3. Install the clutch master cylinder.
CCheck the rust, pitting and scoring of the clutch hose and
tube.
INSTALLATION cous
1. Install the clutch tube (clutch release cylinder side).
‘4, Install the push rod to the clutch pedal.
5. Bleed the system.
DISASSEMBLY | erouss
1. Flemove the piston stop ring.
2 (Refer to the components of the master cylinder)
2. Pullout the push rod and piston assembly.
nore
Be careful not to damage the master cylinder body
and piston assembly.
INSPECTION cexcue
1. Cheok the inside of the cylinder body for rust, pitting
scoring.
‘Check the piston cup for wear or distortion.
(Check the piston for rust, pitting or scoring.
‘Check the clutch tube tine for obstructions.
Measure the clutch master cylinder inside diameter
with a cylinder gauge, and the piston outside diameter
with a micrometer.CH-10
REASSEMBLY xan
1. Apply the specified fluid to the inner surface of the
cylinder body and to the outside ofthe piston assemn-
bly.
‘Spocified fluid : BRAKE FLUID DOT 3 or DOTA
2, Install he piston assembly.
3. Install the piston stop ring
4, Install the push rod assembly. (Refer to the compo-
‘nents ofthe clutch master cylinder.)
5. Install the ciutch hose on the cylinder body.
CLUTCH SYSTEMCLUTCH SYSTEM oe
CLUTCH PEDAL
COMPONENTS | cane
128 100-260, 1420)
Bushing
‘Clutch pedal
8-10 (80-100, 6-7)
‘TORQUE : Nm (kg-cm, Ib-tt)CHA12
CLUTCH SYSTEM
REMOVAL ese
41. Remove the master cylinder mounting nut. 1
INSPECTION occ
|. Check the clutch pedal shaft and bushing for wear,
Check the clutch pedal for bending or distortion,
(Check the return spring for damage or deterioration.
Check the clutch pedal pad for damage or wear,
Measure the clutch pedal height (from the face of the
Pedal pad to the floorboard).
Standard value : (A) 166.7 mm (6 in
(Chtch pedal height
Hf the clutch pedal height is not within the standard
value range, adjust as follows :
* Tum and adjust the bot, then secure by tighten
Jing the lock nut.
168,
Q) caution
After the adjustment, tighten the bolt until it
‘Teaches the pedal stopper, and then tighten the
lock nut.
* Turn the push rod to agree with the standard
value and then secure the push rod with the lock
utCLUTCH SYSTEM
Q caution
When adjusting the clutch peda height, be careful
‘not to push the push rod toward the master cylin-
dor.
7. Alter completing the adjustments, check that the
Clutch pedal free play (measured at the face of the
pedal pad) is within the standard value ranges.
‘Standard value : (B) 6-13 mm (0.24-0.52 in)
8. Ifthe clutch pedal free play do not moet with the stan-
dard values, it may be the result of either air in the
hydraulic system or a faulty clutch master cylinder.
Bleed the air or disassemble and inspect the master
cylinder or clutch.
‘Chich pedal tee play
IGNITION LOCK SWITCH INSPECTION
(Check for continuity between terminals.
Sana Toma! 7 2
Pushed
Free}
1202030m
20 s0.3mm
CH-13
INSTALLATION scree:
1. Apply the multi-purpose grease and install the pedal
‘Support bot.
‘Specified lubricants :
SAE J310a, Chassis grease, NLGI-No-t
2. Install the pedal supprot member mounting bolt.CH -14 CLUTCH SYSTEM
CLUTCH COVER AND DISC
COMPONENTS | ccosecr
15:22 (150-220, 11-16)
Clutch aise
‘TORQUE : Nm (kg-cm,|b-ft)
REMOVAL ncouo
1. Drain the clutch fluid and transaxle gear ol.
2. Remove the transaxle assembly, (Refer to the “TR"
‘group)
3. _Insertthe special too! (09411-25000) inthe clutch dise
to prevent the disc from fallingCLUTCH SYSTEM
CH~5
4, Loosen the bolts that attach the clutch cover to the
‘lywhee! in a star pattern.
5, Loosen the bolts in succession, one or two turns at a
time, to avoid bending the cover tlange.
Q caution
DO NOT clean the clutch disc or release bearing
with cleaning solvent.
99411-25000
INSPECTION komo
CLUTCH COVER ASSEMBLY
1. Check the diaphragm spring end for wear and uneven
height.
2. Check the pressure plate surtace for woar, cracks and,
color change.
‘3. Check the rivets for looseness and replace the clutch
cover assembly if necessary.
CLUTCH DISC
41. Chepk the clutch facing for loose rivets, uneven con-
tact,'deterioration due to seizure, adhesion of oil, or
‘grease, and replace the clutch disc if defective.
2. Measure the thickness of the disc when free.
3. Check for the torsion spring play and damage and it
detective, replace the clutch disc.
‘4, Clean the splines on the input shaft and install the
clutch disc.
IT the disc does not slide smoothly or if play is excos-
sive, replace the clutch disc andior the input shatt.
CLUTCH RELEASE BEARING
Q caution
‘The release bearing Is packed with grease. Donot
use cleaning solvent or oll.
1. Check the bearing for seizure, damage or abnormal
noise. Also chack the diaphragm spring contacting,
points for wear.
2. Replace the bearing if the release fork contacting
points are worn abnormally.
CLUTCH RELEASE FORK
It there is abnormal wear at the point of contact with the
bearing, replace the release fork assembly.
INSTALLATION. sossco
1. Apply multipurpose grease to the release bearing
‘contact surfaces and tho release cylinder contact
‘surface of the clutch release fork assembly.
Q cauTion
When Installing the clutch, apply grease to each
part, but be careful not to apply excessive grease.
Mean cause clutch slippage and judder.CH-A6
2. Apply muttipurpose grease into the groove of the re-
lease bearing
‘Grease : CASMOLY L9508
3. Apply multipurpose grease to the clutch release lever
fulcrum contact surface ofthe clutch release fork as-
sembly.
Grease : CASMOLY 19508
4. Clean the surfaces ofthe flywheel and pressure plate
thoroughly with fine sandpaper or crocus cloth, and
make certain that al il or grease has been removed.
5. Apply a small amount of multipurpose grease to the
‘clutch disc splines and input shaft splines.
Grease : CASMOLY L9508
& caution
Do not apply more grease than necessary. Too
‘much grease could cause clutch slip or judder.
6. Using the special tool (09411-25000), install the
Clutch disc to the flywheel. When installing the clutch
diso, be sure that the surface having the manufac-
tures stamp is towards the pressure plate side.
7. Install the the clutch cover assembly onto the flywheel
‘and install the six (6) bolts through the clutch cover
into the flywheel
8. Diagonally tighten the bolts 15.22 Nm (180-220
kgrom, 11-15 lb).
Tighten the bolts by one or two turns at a time, in
succession, to avoid bending the cover flange.
9. Remove the special tool
10. Install the transaxle. (Refer to the "TR" group.)
11. Adjust the clutch pedal free-play.
CLUTCH SYSTEMCLUTCH SYSTEM CH-17
CLUTCH RELEASE CYLINDER
COMPONENTS cress
‘Chitch release cylinder
‘Bleeder screw
o
tum sping
Piston
Release oyinder Boot
Vave sig Push rod
‘Valve plato ————{0}
es
xpecir £09
Gasket
Union bot
REMOVAL sco.
1. Disconnect the clutch tube,cl
CLUTCH SYSTEM
2, Remove the clutch release cylinder mounting bolt
INSPECTION sorox0
1. Check the clutch release cylinder for fluid leakage.
2. Check the clutch release cylinder boots for damage.
DISASSEMBLY orm
1. Remove the clutch hose, valve plate, spring, push rod
and boot.
2. Remove any dirt from the piston bore opening of the
release cylinder,
8. Remove the piston from the release cylinder using
compressed air.
&\ caution
1. Cover the release cylinder with rags to pre-
vent the piston from popping out and causing
injury.
2, Apply compressed air slowly to prevent the
fluid from splashing in your eyes or on your
‘kin.
INSPECTION sonra
1. Check the release cylinder bore for rust and damage.
‘Measure the release cylinder bore at three locations
(bottom, middle and top) with a cylinder gauge and
replace the release cylinder assembly if the bore-to-
piston clearance exceeds the limit.
Limit: 0.15 mm (0.006 in.)
REASSEMBLY saxcece
1. Apply specified brake fluid to the release cylinder bore
‘and the outer surface ofthe piston and piston cup, and.
push the piston cup assembly into the cylinder.
Use the specified fluid: Brake fluid DOT or DOT 4
2. Install the valve plate, push rod and boot.CLUTCH SYSTEM CH-19
INSTALLATION | wrzcca
1. Coat the clevis pin withthe specified grease.
‘Specified grease : CASMOLY L9508